The significant advance in the boosted fabrication speed and printing resolution of additive manufacturing (AM) technology has considerably increased the capability of achieving product designs with high geometric complexity and provided tremendous potential for mass customization. However, it is also because of geometric complexity and large quantity of mass-customized products that the prefabrication (layer slicing, path planning, and support generation) is becoming the bottleneck of the AM process due to the ever-increasing computational cost. In this paper, the authors devise an integrated computational framework by synthesizing the parametric level set-based topology optimization method with the stereolithography (SLA)-based AM process for intelligent design and manufacturing of multiscale structures. The topology of the design is optimized with a distance-regularized parametric level set method considering the prefabrication computation. With the proposed framework, the structural topology optimization not only can create single material structure designs but also can generate multiscale, multimaterial structures, offering the flexibility and robustness of the structural design that the conventional methods could not provide. The output of the framework is a set of mask images that can be directly used in the AM process. The proposed approach seamlessly integrates the rational design and manufacturing to reduce the numerical complexity of the computationally expensive prefabrication process. More specifically, the prefabrication-friendly design and optimization procedure are devised to drastically eliminate the redundant computations in the traditional framework. Two test examples, including a free-form 3D cantilever beam and a multiscale meta-structure, are utilized to demonstrate the performance of the proposed approach. Both the simulation and experimental results verified that the new rational design could significantly reduce the prefabrication computation cost without affecting the original design intent or sacrificing the original functionality.
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April 2019
Research-Article
Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing
Long Jiang,
Long Jiang
Department of Mechanical Engineering,
New York, NY 11794-2300
e-mail: long.jiang@stonybrook.edu
The State University of New York at Stony Brook
,New York, NY 11794-2300
e-mail: long.jiang@stonybrook.edu
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Hang Ye,
Hang Ye
Department of Industrial and Systems Engineering,
New York, NY 14260-2050
e-mail: hye2@buffalo.edu
The State University of New York at Buffalo
,New York, NY 14260-2050
e-mail: hye2@buffalo.edu
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Chi Zhou,
Chi Zhou
Department of Industrial and Systems Engineering,
New York, NY 14260-2050
e-mail: chizhou@buffalo.edu
The State University of New York at Buffalo
,New York, NY 14260-2050
e-mail: chizhou@buffalo.edu
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Shikui Chen
Shikui Chen
1
Department of Mechanical Engineering,
New York, NY 11794-2300
e-mail: shikui.chen@stonybrook.edu
The State University of New York at Stony Brook
,New York, NY 11794-2300
e-mail: shikui.chen@stonybrook.edu
1Corresponding author.
Search for other works by this author on:
Long Jiang
Department of Mechanical Engineering,
New York, NY 11794-2300
e-mail: long.jiang@stonybrook.edu
The State University of New York at Stony Brook
,New York, NY 11794-2300
e-mail: long.jiang@stonybrook.edu
Hang Ye
Department of Industrial and Systems Engineering,
New York, NY 14260-2050
e-mail: hye2@buffalo.edu
The State University of New York at Buffalo
,New York, NY 14260-2050
e-mail: hye2@buffalo.edu
Chi Zhou
Department of Industrial and Systems Engineering,
New York, NY 14260-2050
e-mail: chizhou@buffalo.edu
The State University of New York at Buffalo
,New York, NY 14260-2050
e-mail: chizhou@buffalo.edu
Shikui Chen
Department of Mechanical Engineering,
New York, NY 11794-2300
e-mail: shikui.chen@stonybrook.edu
The State University of New York at Stony Brook
,New York, NY 11794-2300
e-mail: shikui.chen@stonybrook.edu
1Corresponding author.
Manuscript received March 26, 2018; final manuscript received January 3, 2019; published online February 28, 2019. Assoc. Editor: Qiang Huang.
J. Manuf. Sci. Eng. Apr 2019, 141(4): 041007 (8 pages)
Published Online: February 28, 2019
Article history
Received:
March 26, 2018
Revision Received:
January 3, 2019
Accepted:
January 4, 2019
Citation
Jiang, L., Ye, H., Zhou, C., and Chen, S. (February 28, 2019). "Parametric Topology Optimization Toward Rational Design and Efficient Prefabrication for Additive Manufacturing." ASME. J. Manuf. Sci. Eng. April 2019; 141(4): 041007. https://doi.org/10.1115/1.4042580
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